With the continuous development of technology and breakthroughs, five-axis machining technology and equipment are expected further to highlight their core value in the modern manufacturing industry, helping the manufacturing industry to achieve higher precision, higher efficiency and an intelligent level, to promote the upgrading of related key industries and change.
1. Introduction
Five-axis machining technology is a kind of machining technology in which the index-controlled tool moves in five independent axes. Compared with the traditional three-axis machining, it can cut on more complex surfaces and shapes, reduce the number of workpiece clamping, and effectively improve efficiency and machining accuracy. In addition, five-axis machining technology mainly relies on five-axis machine tools to complete the five-axis machine tool multi-axis linkage, enabling the CNC tool can process different angles and attitudes to the complex parts processing, especially in the machining of irregular planes, to avoid interference, over-cutting and under-cutting phenomena.
In the current era of industrial chain and supply chain reshaping, with the development of the high-end manufacturing industry, five-axis machining technology and equipment have become an important tool for the high-end manufacturing industry by virtue of their advantages in high-precision and complex parts machining, which has important strategic development significance. In this paper, we will discuss the development status, challenges and future development trend of five-axis machining technology and equipment.
2. Definition, Processing Principles and Classification of 5-Axis Machines
2.1 Definition
Five-axis machine tool is mainly composed of a CNC system, servo drive, the main body of the machine tool and other auxiliary devices, which is a kind of CNC machine tool with high technological content and high precision. It is usually equipped with a high-performance CNC system, which realizes accurate control of complex trajectories through advanced algorithms. Under the control of the CNC system, there are at least 5 coordinate axes coordinated movement for processing, which can make the position and attitude of the CNC tool relative to the workpiece more flexible and diversified, and can process a variety of complex curved surfaces and shaped parts, which are widely used in aerospace, automotive, energy and electric power, low-altitude economic equipment, humanoid robotics equipment, ships, medical equipment, precision molds, precision instruments and optics, electronics manufacturing and other high-end manufacturing fields.
2.2 Processing Principle
Five-axis machining technology is based on five-axis machine tool realization, the basic working principle involves complex mechanical movement and CNC control.
(1) Motion principle of a 5-axis machine tool
A 5-axis machine tool has 5 individual motion axes, including 3 linear coordinate axes X, Y, Z, and 2 rotary coordinate axes, i.e., 2 of A, B, C. It is able to accurately cut and process multiple surfaces and complex shapes of the workpiece.
(2) Synergy between linear and rotary coordinates.
The linear coordinate X, Y, and Z axes and the rotary coordinate A, B, or C axes cooperate to realize multi-directional machining. Among them, the direction of the machine tool spindle axis or the vertical direction of the table for clamping the workpiece for the Z-axis, and the workpiece mounting surface parallel to the horizontal plane, or in the horizontal plane to choose the direction of the rotary axis perpendicular to the workpiece for the X-axis, away from the axis of the spindle for the direction of the positive direction, the Y-axis is perpendicular to the X-axis and the Z-axis, and with the two together constitute a right-handed orthogonal coordinate system, and the specific direction of which depends on the structure of the machine tool and the way of installation of the workpiece. The specific direction depends on the structure of the machine and the installation method of the workpiece. In the rotary coordinate, rotating around the X-axis is the A-axis, rotating around the Y-axis is the B-axis and rotating around the Z-axis is the C-axis. Five-axis machine tools are mainly in the form of XYZ+A+B, XYZ+A+C and XYZ+B+C. Different combinations are suitable for different machining scenarios.
2.3 Classification
(1) According to the linkage can be divided into two kinds
One is 5-axis linkage, that is, 5 axes can be linked at the same time, the other is 5-axis positioning machining, which is actually 5-axis 3-linkage, that is, 2 rotary axes rotating and positioning, and only 3 axes can be linked to machining at the same time, commonly referred to as 3+2 mode. Five-axis five linkage with RTCP function, that is, the tip point following function, can maintain the center point of the CNC tool and CNC tool and the workpiece surface of the actual contact point unchanged, in the machining process, the control of the workpiece and the CNC tool movement of the five degrees of freedom can also be simultaneous movement, so as to process an arbitrary surface, and five-axis three linkage, the other 2 axes only play a positioning function. Five-axis linkage processing and five-axis positioning processing applicable to industry objects are different, linkage processing is suitable for surface processing, such as various types of complex mold cavity parts of the processing, and positioning processing applicable to different parts of the workpiece plane, holes and slots and other surface processing.
(2) According to the spindle position relationship is divided into three categories
Horizontal, vertical and vertical-horizontal conversion. Among them, the vertical type is more common, the structure is characterized by the spindle being vertically arranged. The spindle characterizes horizontal structure is horizontally arranged, in the height direction occupies relatively small space, and special flap milling five-axis machine tools can be categorized as horizontal. The structure of vertical and horizontal conversion is characterized by the spindle that can be converted between vertical and horizontal, with a variety of motions. Due to its relatively complex structure, one needs to take into account the space requirements of vertical and horizontal conversion.
(3) The relationship between the rotary spindle and linear motion is divided into three main categories
Double rotary table, one rotary and one pendulum and double pendulum head. The double rotary table (A+B as an example) is suitable for the processing of small turbines, impellers and small compact molds, etc.. By superimposing an A-axis rotary table on a B-axis rotary table, high-precision machining of complex-shaped workpieces can be realized through multi-axis coordinated movement. A rotation and a pendulum (divided into A + B, B + C, usually called the cradle type), this structural form of good rigidity, high precision, to meet the processing needs of workpieces requiring high processing accuracy. In the aerospace field of some key components processing, a turn pendulum structure of the five-axis machine tool can play an important role. Double pendulum head structure worktable is large, generally gantry (or bridge), the rotating part is in the head, suitable for processing large workpieces, in the field of large-scale mold manufacturing, ship diesel engines and energy and power manufacturing, double pendulum head structure of the large-scale five-axis machine tools can be based on the characteristics of its large worktable, and efficiently complete the task of large workpieces processing.
(4) According to the application field can be divided into
Material reduction, material increase and composite five-axis machine tools. Subtractive 5-axis machine tools refer to the machining method of obtaining the final part shape by removing the blank material. Five-axis additive machine tools usually use a laser as the energy source, through the powder/wire feeding device, which will deposit material (metal powder/wire, thermoplastic materials, etc.) layer by layer, combined with a five-axis linkage to achieve a complex three-dimensional structure of the unsupported molding. The composite 5-axis machine tool integrates various processing and manufacturing methods, such as additive, subtractive, laser and ultrasonic processing, on a single machine tool, which can be flexibly switched as needed during processing to realize efficient processing. For example, the general shape of the part is first constructed by additive manufacturing, and then it is finished by subtractive machining to improve the accuracy and surface quality of the part.
In summary, five-axis machine tools are categorized in a variety of ways, and different categorizations correspond to different application scenarios and processing needs, providing diversified solutions for high-end manufacturing.
3. Market Pattern of 5-axis Machine Tools
Five-axis machine tools, as the key equipment of the high-end manufacturing industry, its market pattern is influenced by many factors such as technology, brand and application areas.
Machine tool brands from countries and regions such as the EU, the U.S., and Japan dominate the high-end market, while machine tool brands from South Korea and other countries occupy some of the middle and low-end markets. Countries and regions such as the EU, the United States, Japan and other leading machine tool technology, is the birthplace of five-axis machine tool technology, has long occupied the high-end market, by virtue of the deep accumulation of technology and continuous innovation, product precision, stability and automation degree is extremely high, strong brand influence, through the provision of customized solutions and perfect service, and continue to consolidate the position of the high-end market. Japan’s five-axis machine tool technology is advanced and diverse, focusing on product reliability and ease of use, and in the global market, its share is considerable. China, Taiwan, and South Korea products high-quality and low-priced products, with strong stability, and products due to cost-effective and occupy a certain share in the global low-end market.
4. Five-axis Machining Technology and Equipment Development Status
High-end 5-axis machining technology and equipment have been in the leading position in the following 5 aspects.
(1) Technology level
① High precision machining. High-end 5-axis machine tools have higher positioning accuracy, thus ensuring that the positioning accuracy of CNC tools in the machining process reaches the micron or even submicron level. At the same time, it also has a better repeat positioning accuracy and can maintain stable machining accuracy and consistency.
② High-speed machining. High-end five-axis machine tools use iterative optimization of the machine structure, the configuration of ultra-high spindle speed, so as to achieve high-speed and efficient machining.
③ Compound machining. Able to realize a variety of machining methods of composite processing, improve processing flexibility and efficiency.
④ Complex machining. Equipped with a high-performance spindle system and advanced CNC tooling technology, it realizes high-efficiency machining of complex curved surfaces, deep grooves, narrow grooves, recessed areas and other hard-to-reach parts, and is suitable for mass production and machining of complex parts.
(2) Performance
Mainly reflected in the stability and reliability of the machine tool. High-end five-axis machine tools are usually high-strength, high rigidity and optimized mechanical structure design and quality materials, the overall rigidity of the machine tool is high, good stability at the same time vibration-absorbing ability to withstand greater cutting force and impact, to ensure that the machine tool in high-speed, high-load machining conditions of the stability of the machine tool to reduce the vibration and deformation on the machining accuracy of the impact. High-end five-axis machine tools have a more advanced CNC system and fault diagnostic functions, which can reduce unnecessary downtime and improve the reliability and utilization of machine tools. According to statistics, the average time between failures of well-known foreign brands of five-axis machine tools is more than 5000h, up to 10000h.
(3) Functional configuration
High-end five-axis machine tools are usually equipped with Siemens, Fanuc and Heidenhain and other internationally renowned brands of CNC systems, or equipped with its brand of CNC systems, capable of realizing complex programming and control functions, with high-precision measurement system, equipped with high-precision measuring instruments and sensors, can be automatically compensated for and adjusted, configure a diverse range of CNC tooling system to support a wide variety of types and specifications of the CNC tooling to improve the machining efficiency and reduce tool loss. The configuration of a diversified CNC tooling system supports a variety of types and specifications of CNC tools, which improves the machining efficiency and reduces tool loss. The moving parts and bed of some brands of machine tools adopt constant temperature cooling, which can continuously maintain the thermal stability of the machine tools and ensure that the machine tools are not affected by temperature changes during machining and maintain high-precision machining.
(4) Market pattern
High-end five-axis machine tools occupy a large market share, especially in high-end manufacturing fields such as aerospace, mold, energy and power and medical equipment. It also has a strong advantage in brand influence, with high visibility and reputation, and has established a good brand image, which is trusted and recognized by high-end customers.
(5) Product R&D
Famous 5-axis machine tool manufacturers usually invest a lot of money and manpower in technology research and development, constantly promote the innovation and development of 5-axis machine tool technology, and are committed to researching new machining processes, control technology and material applications to meet the changing market demand and improve the competitiveness of their products.
5. Key Technologies
5.1 Advances in Drive Technology
The development of five-axis machine tool drive technology plays a crucial role in the improvement of machining performance. In recent years, with the continuous progress of science and technology, drive technology has also made remarkable progress.
In terms of motor technology, linear motors and torque motors are more and more widely used, and have developed from servo motors and ball screw drives for linear motion (X/Y/Z axes) to the current linear motor drives, and direct-drive torque motors are used for rotary motion (A and C axes), which significantly improves the speed, dynamic performance and positioning accuracy of 5-axis machine tools.
5.2 Development of Control Technology
The innovation of five-axis machine tool control technology plays a decisive role, which is mainly reflected in the development of CNC systems and optimization of motion control algorithms in two aspects.
In the field of global high-end five-axis CNC system, Germany Siemens, Japan Fanuc and other industry giants, representing the highest level of CNC system, established a high technical barriers, long-term dominance of the market, with its advanced technology and mature technology, in the technological research and development, product performance and market share to maintain a leading edge. At present, CNC systems are integrated with artificial intelligence technology to realize intelligent programming, adaptive machining and real-time fault diagnosis, which greatly improves the level of machine tool intelligence and production reliability.
5.3 Optimization of Motion Control Algorithm
The optimization of the motion control algorithm plays an important role in the machining accuracy and efficiency of 5-axis machine tools. Five-axis machine tools require complex spatial geometric operations and coordinated movement of five axes simultaneously when machining workpieces with complex geometrical shapes. Due to the addition of rotary motion, the workload of interpolation operations is increased, so the CNC system is required to have high computing speed and precision.
5.4 Application of 5-axis machining software
Five-axis machining software plays an extremely important role in programming, simulation and optimization.
(1) Programming
Professional five-axis programming software is mainly based on foreign brands, providing powerful programming support for five-axis machining. This software can be based on the geometry of the parts and machining requirements, automatically generate the optimal cutting path, effectively reducing process optimization and human adjustment time, and improve programming efficiency.
(2) Simulation
Five-axis machining programming is difficult, the spatial trajectory of the synthetic movement is complex and abstract. The simulation function of 5-axis machining software can visualize the CNC tool path and machining process, check the machining path and preview the machining results, which can effectively reduce the risk of collision and error, so as to achieve the purpose of optimizing the machining path, shortening the machining time and improving the accuracy of the workpiece.
(3) Optimization
Five-axis auxiliary programming software plays a vital role in optimization. This type of software typically consists of three main components: the backend processor, the front-end interface, and the post-processor. The backend processor is responsible for generating toolpaths, calculating cutting parameters, and resolving potential issues such as interference, collisions, and constraints in five-axis machining. The front-end interface serves as the platform for user interaction with the software, allowing users to input part geometry, process requirements, and machining constraints, as well as to preview and edit the operations visually. The post-processor converts the generated toolpaths and related information into code that the CNC system can recognize.
6. Key Application Areas
6.1 Aerospace
(1) Application status
① Processing of complex parts. In the aerospace field, the shapes of structural parts such as blades, blade disks, impellers and magazines of aircraft engines and wing beams, frames and ribs of fuselages are extremely complex. Five-axis machine tools can realize multi-axis linkage and accurately process these complex curved surfaces and three-dimensional parts to ensure their high accuracy and quality.
② Processing of difficult-to-machine materials. Aerospace parts often use glass fiber, aluminum alloys, titanium alloys, high-temperature alloys and carbon fiber composites and other difficult-to-machine materials, five-axis machine tools with its high rigidity, high speed and high precision features, while attached to the followers of the dust collection, detection systems and other components, can effectively deal with the challenges of processing these materials, to achieve efficient cutting and forming processing.
③ Improve machining efficiency and quality. Five-axis machining can complete the machining of multiple surfaces and feature structures in a single clamping, reducing the number of clamping and the accumulation of errors, improving productivity and machining accuracy, while also ensuring the consistency and interchangeability of parts.
(2) Application trends
① Toward higher precision and efficiency. With the development of aerospace technology, the requirements for part accuracy and production efficiency continue to improve. The future will optimize the machine structure, enhance the performance of the control system further to improve the machining accuracy of five-axis machine tools, to achieve more efficient production.
② Intelligent and automated degree of improvement. The introduction of artificial intelligence, big data and other technologies so that the five-axis machine tool with adaptive processing capabilities, according to the material, shape and machining state of the parts automatically adjust the processing parameters, to achieve an intelligent machining process. In addition, the integration of five-axis machine tools with robots and other automation equipment can realize the lighthouse factory.
③ Synergistic development with additive manufacturing. Five-axis machining technology will be combined with additive manufacturing technology to form a complementary manufacturing model. Additive manufacturing is used to manufacture complex-shaped parts blanks rapidly, and five-axis machine tool machining carries out subsequent fine machining and surface treatment to improve the performance and quality of parts.
(3) Future Development
① Technology innovation continues to deepen. Artificial intelligence, big data, cloud computing and quantum technology and other emerging technologies will be more widely used in the aerospace field, promoting the intelligent, digital and networked development of aircraft design and manufacturing, operation and management.
② Accelerated commercialization process, cooperation and competition co-exist. The commercial aerospace market and low-altitude economy will continue to grow rapidly, and more enterprises will enter the fields of commercial launch, satellite manufacturing and low-altitude industry.
6.2 Automobile
(1) Application status
① Full coverage of parts processing. Five-axis machine tools are widely used in the manufacture of key parts such as automobile engines, transmissions, motor shells, battery shells, battery trays, integrated rear chassis die-castings, subframes, front compartments and brake systems, etc., which can process parts to meet the needs of high-precision, lightweight design, while improving manufacturing quality and efficiency.
② Five-axis laser cutting machine tools can be used to cut new energy vehicles’ crash beams, chassis, B-pillar and other complex-shaped parts.
(2) Application Trends
① Intelligent manufacturing deep integration. The use of the Internet of Things to realize the networking of equipment to build smart factories, so that the production process can be monitored and traced, can be integrated with robots, automated logistics systems, and the formation of automated production lines.
② High precision and high efficiency continue to improve. Machine tool manufacturers will continue to optimize the structure of the machine tool, improve the precision and rigidity of the transmission system, develop a more advanced control system, improve the machining precision and quick shift speed of the five-axis machine tool, and at the same time, improve the cutting efficiency by improving the tool material and tool design.
(3) Future Development
① Technology innovation continues to deepen. Intelligent driving will gradually spread in the future, the market for programmable electric vehicles and plug-in hybrid vehicles will expand, the 800V high-voltage platform will gradually spread, and solid-state batteries will accelerate mass production.
② Globalization and territorialization will go hand in hand. The globalization strategy of automobile enterprises will shift to localized manufacturing, build a localized operation system, and strengthen localized R&D and brand building.
Diversification of the competitive landscape. From “price competition” to “value competition”, car companies will meet the diversified needs of consumers through technological innovation, differentiated marketing. In the future, the entire automotive industry reshuffle will accelerate, the advantage of the head of the automobile enterprises will expand, and the competition and cooperation between the new car-making forces and traditional automobile enterprises will coexist.
6.3 Energy and Power
(1) Application status
① Turbine impeller and blade processing. The shape and size of turbine blades are extremely critical to the efficiency and performance of the turbine. Five-axis machine tools can accurately process turbine blades of various complex shapes, ensure the profile accuracy and surface quality of the blades, and improve the power generation efficiency of the turbine.
② Generator stator and rotor machining. The stator and rotor of a generator usually have complex grooves and winding structures. Five-axis machine tools can realize high-precision machining of the stator and rotor to ensure a uniform air gap between the stator and rotor and improve the performance and reliability of the generator.
③ Wind power industry. Wind turbine blades are characterized by large size and complex curved surfaces, and five-axis machine tools can carry out high-precision machining of blade molds to ensure the aerodynamic performance and structural strength of the blades. In addition, five-axis machine tools can also be used for processing wind power equipment in the gearbox, spindle and other key components.
④ Nuclear power industry. Nuclear reactor pressure vessel, main pump, core components and evaporator tube plate and other key components of complex shape, and the machining accuracy and quality requirements are extremely high. Super heavy and large five-axis gantry machine tools can meet the processing needs of these parts to ensure the safe and stable operation of nuclear power plants.
(2) Application Trends
① The demand for high-precision, continuous and stable processing has increased. The energy and power industry on machine tool equipment parts of high precision requirements, and the need for equipment with extraordinary stable operation to meet the nuclear power, hydropower and other key equipment parts processing needs, to ensure efficient and safe operation of power equipment.
② Adapt to the processing of new materials. With the energy and power industry, high-performance composite materials, new alloys and other new materials continue to be used, five-axis machining technology needs to continue to develop new machining processes and tools to adapt to the processing requirements of new materials, giving full play to the performance advantages of new material components.
(3) Future Development
① Accelerated transformation of energy structure. The proportion of new energy in the energy structure will continue to increase, wind power, photovoltaic, and other renewable energy will maintain the rapid development trend, while the energy storage technology will continue to mature and popularize, in order to solve the intermittent and fluctuating new energy generation.
②Intelligent and digitalization level. Smart grid, virtual power plant will be more widely used and developed, the level of intelligence and digitalization of the grid will continue to improve, to achieve efficient allocation and use of energy.
③ Multi-energy complementary and synergistic development. Traditional energy and new energy will realize multi-energy complementary and synergistic development, and jointly guarantee the stability and security of energy supply.
6.4 Low Altitude Economic Equipment
(1) Application status
① UAV core parts processing. At present, the body and wings of UAVs use a lot of PMI foam, carbon fiber and other composite materials, and the 5-axis machine tool can efficiently mill composite parts such as the body, wings, fairings, main bearing structures and wing box segments, to ensure the precision of the parts and ensure the accuracy and performance of the UAV assembly.
②Electric Vertical Take-off and Landing Vehicle (eVTOL) core parts processing. Electric vertical take-off and landing vehicle fuselage frame, wing connecting parts, propeller blades and other complex structural components and parts of the machining accuracy and complex surface molding requirements; five-axis machine tools can realize the precision machining of these parts.
③Flying car parts processing. Flying car fusion of automobile and aircraft features, its parts not only meet the performance requirements of the car, but also meet the standards of low-altitude aircraft. Five-axis machine tools can be used to process key components of flying cars, such as the folding wing mechanism, power system components.
(2) Application Trends
① Enhance the efficiency and quality of composite material processing. With the low-altitude economic field of equipment lightweight requirements continue to improve, the demand for composite materials continues to increase, five-axis machine tools will continue to optimize the processing of composite materials, the development of more suitable for processing composite materials, the development of cutting tools, configure various types of follower dust-absorbing parts, effective protection of the processing environment, reduce processing costs and scrap rate.
② Flexible production applications will be more extensive. Low-altitude economic equipment market demand diversification, small batch, and multi-species production will become the mainstream of the market. Five-axis machine tools will be integrated with industrial robots, automated logistics systems, etc., the formation of flexible manufacturing units or automated production lines, with the ability to quickly switch between the processing of different products to improve the flexibility and adaptability of production.
(3) Future development
Technological innovation to promote performance enhancement, enterprises in the power industry will continue to develop more efficient, more energy-saving electric drive systems to improve the range and load capacity of the aircraft. Application scenarios continue to expand, in addition to the existing logistics and distribution, agriculture and forestry plant protection and emergency rescue applications, low-altitude economic equipment will be more widely used in urban air transportation, air tourism and medical emergency and other fields. At the same time, the construction of general-purpose airports, take-off and landing points, charging stations and other related infrastructure will continue to improve, providing strong support for the development of low-altitude economic equipment.
6.5 Humanoid Robot
(1) Application status
① High-precision parts processing. Humanoid robot joints, arm bar, base, arm, leg and joint frame and other parts with high precision and surface roughness requirements, five-axis machine tools can complete the spatial structure of complex parts processing.
② Complex structure manufacturing. There are many irregular shapes and cavities inside the humanoid robot. Five-axis machine tools can process all kinds of gearboxes, bearings, motor mounts and precision reducer housing inside the robot to ensure accurate transmission and coordination between parts.
③ Processing of lightweight materials. In order to improve the efficiency and flexibility of humanoid robots, which often use aluminum, magnesium alloy, and other new lightweight high-performance materials, five-axis machine tool processing can be optimized to reduce the deformation of the material while maintaining high precision and high surface quality.
(2) Application trends
① Enhancement of composite machining capabilities. Future five-axis machining technology may be combined with additive manufacturing, laser processing and other manufacturing technologies, such as electrochemical machining, the formation a multi-process composite machining system, to achieve more complex humanoid robot parts manufacturing.
② Higher precision and efficiency. With the continuous progress of technology, five-axis machine tool precision and efficiency will be further improved to meet the requirements of humanoid robots on the parts of higher precision.
(3) Future development
The deep integration of artificial intelligence enables robots to more accurately understand and process a variety of information, such as voice, image, text, etc., and make smarter decisions. Hardware performance continues to improve, with the core components of miniaturization, high-performance development, so that humanoid robots move more flexibly and respond more quickly. The application of new materials will increase, the application of high-strength, lightweight alloy materials and new composite materials in the reduction of energy consumption at the same time, improve the life of the robot and adaptability, the application field will continue to expand, in industrial manufacturing, medical education and family services and other fields will have more industrialized humanoid robot applications.
6.6 Molds
(1) Application status
① Processing of plastic molds. In the mold manufacturing of cell phone shells, home appliance shells and other plastic products, five-axis machine tools are able to process complex cavities and fine patterns, improve the precision and surface quality of the mold, so that the appearance and dimensional accuracy of plastic products are guaranteed.
② Processing of stamping molds. Automobile cover parts, hardware products and other stamping molds are complex, requiring high-precision processing. Five-axis machine tool can realize the accurate processing of mold profiles, improve the forming quality of stamping parts and the service life of the mold.
③ die-casting mold processing, for aluminum alloy, zinc alloy and other die-casting mold, five-axis machine tool can process the complex runner, cavity and other structures, to ensure the precision of the mold and heat dissipation performance, improve the quality of die-casting products and production efficiency, broaden the degree of freedom of mold design.
(2) Application trends
① High precision and high efficiency continue to improve. Machine tool manufacturers will continue to optimize the structure and control system to improve processing accuracy and fast-moving speed. Tooling technology will also continue to improve, to further improve cutting efficiency and achieve a higher material removal rate.
②Intelligent and automated degree of improvement. Subsequent five-axis machines can automatically optimize machining parameters and tool paths. In addition, combined with the Internet of Things, it can realize remote monitoring of equipment, fault early warning and diagnosis, and it can also be integrated with the production line to realize the full automation of loading and unloading, material handling and so on.
③ Deep integration with digital technology. Five-axis machine tools and CAD/CAM/CAE and other software seamlessly, to achieve the integration of mold design, programming and processing. The use of virtual simulation technology to simulate the processing process, find and solve problems in advance, and reduce the cost of trial and error.
(3) Future development
① High-performance mold. Key areas of the mold precision requirements will be higher, while the gradual application of new mold steel, cemented carbide and other new materials in the field of molds will enhance the hardness of the mold, wear resistance and corrosion resistance.
② Green environmental protection. Follow-up mold companies need to use environmentally friendly materials and processing, strengthen waste treatment and recycling, promote resource recycling, and promote the sustainable development of the industry.
③ integration. The future of mold integration and integration of higher requirements, integrated molds can be integrated into a number of mold functions, simplify the production process, improve efficiency and product quality.
Customized service. Downstream industry demand diversification, customization have become an important trend in the mold industry. Mould companies need to have strong design and manufacturing capabilities, rapid response to the market, to provide high-quality customized products and services, in order to take advantage of the competition.
6.7 Medical Devices
(1) Application status
① Manufacturing of orthopedic implants. Five-axis machine tools are widely used in the manufacture of orthopedic implants such as artificial joints, bone nails and spinal screws. Five-axis machine tools can accurately process titanium alloy and other biocompatible materials to ensure the dimensional accuracy, surface quality and complex structural design of implants, so that they can better match and integrate with human bones.
② Machining of surgical instruments. Five-axis machine tools can be used for the production of scalpels, surgical forceps and puncture needles and other precision surgical instruments, can realize the fine processing of instruments, to ensure the sharpness of their edge, clamping accuracy and flexibility of operation, to improve the accuracy and safety of surgery.
③ Manufacturing of oral medical instruments. Five-axis machine tool processing plays an important role in the manufacturing of oral implants, crowns and bridges and other oral medical devices, which can accurately process personalized oral restorations according to the patient’s oral structure scanning data to meet the needs of different patients.
(2) Application trends
① Higher precision and efficiency. With the continuous improvement of the precision requirements of medical devices, five-axis machining technology will further improve the precision to a sub-micron level or even higher. At the same time, through the optimization of tool paths, improve cutting speed and feed and other operations, to achieve higher machining efficiency.
② Combined with additive manufacturing. Additive manufacturing is used to rapidly manufacture complex-shaped medical device prototypes or parts of the structure, and the five-axis machine tool carries out subsequent fine machining and surface treatment to improve the performance and quality of medical devices.
(3) Future Development
① Market demand continues to grow. The aging of the global population is increasing, and there is a wide demand for medical devices in the fields of chronic disease monitoring and rehabilitation treatment.
② High-end intelligent acceleration. The application of artificial intelligence in medical imaging diagnosis and intelligent health monitoring equipment has deepened. Internet of Things technology enables medical devices to realize remote connection and data transmission, and the application scope of robot-assisted surgery will continue to expand.
6.8 Artwork
(1) Application status
① Sculpture creation and processing. The 5-axis machine tool can accurately process all kinds of complex sculpture shapes according to the designer’s creativity, and improve the production efficiency and artistic value of the sculpture.
② Jewelry processing. Five-axis machine tools in the processing of complex shapes of jewelry can achieve multi-angle cutting and grinding, enhancing the artistic value and beauty of jewelry. In the processing of rings, necklaces and pendants with unique shapes, it can accurately control the processing size and precision, ensure the precision of the jewelry inlay parts, make the gemstone inlay more solid and beautiful, and improve the quality and quality stability of the jewelry, and at the same time, it can process a variety of complex textures and patterns, highlighting the artistic details and uniqueness of the jewelry.
(2) Application trends
① Deep integration with digital design. Through 3D scanning technology to obtain physical models or use design software for creative design, design data directly into the five-axis machine tool, to achieve a seamless connection from design to processing, to improve the accuracy and efficiency of creation.
②High precision and high efficiency continue to improve. With the development of technology, the precision of 5-axis machine tools will continue to improve, enabling finer detailing and higher surface quality.
③ Personalization is becoming more popular. Consumers’ demand for personalized artwork is growing, and five-axis machining technology can easily meet the requirements of personalized customization and process unique artwork quickly and accurately according to customers’ unique needs.
(3) Future Development
① Digitalization and Intelligent Development. Utilizing technologies such as virtual reality (VR) and augmented reality (AR), consumers will be able to immerse themselves in the effect of the artwork before purchase. Various types of intelligent equipment and robots may be used more in the art processing industry to realize automated production and quality control.
② Cross-field integration and innovation. Art and other fields such as technology, fashion and culture are deeply integrated to create artworks with cross-field characteristics.
③Environmental protection and sustainable development. Adopt environmentally friendly materials and green processing techniques to reduce the impact on the environment. For sculpture creation, recyclable and degradable materials may be used more often.
7. Challenges
7.1 Technical Barriers
The R&D and manufacturing of 5-axis machine tools are relatively difficult, and the machine tools have to realize coordinated movements of multiple axes at the same time, which requires high precision and stability. Problems such as the coupling of the axes and the accumulation of errors in the mechanical structure seriously affect the processing quality, and overcoming these technical problems requires machine tool companies to have a profound accumulation of technology and sustained investment in research and development.
7.2 Financial barriers
5-axis machine tools from R&D to production, with huge capital requirements. R&D links need to purchase advanced equipment, the introduction and training of high-end technical personnel. High R&D and production costs make it difficult for many companies to enter the 5-axis machine tool market. At the same time, due to the market-specific demand for five-axis machine tools, companies need to invest a lot of money in marketing and brand building in the early stage, which also increases the financial pressure on new entrants
7.3 Brand Barriers
5-axis machine tools have formed a more stable market competition pattern, some international famous brands have occupied a large market share, new entrants to the market need to pay more efforts to build their brand image and visibility, in order to win the trust and support of customers, and to obtain machine tools in key areas of application and opportunities.
7.4 Market Barriers
5-axis machine tools have a high market access threshold. It belongs to the high-end manufacturing industry, and customers have harsh requirements on product quality and performance. New enterprises need to have a high technical level and strong production capacity to meet these requirements.
8. Future Development Trends
8.1 Technological innovation
(1) Continuous improvement of precision
Manufacturing process upgrading and improvement, machine tool structure iterative optimization, detection and compensation technology is more mature and advanced, all of which can make five-axis machine tool machining accuracy to the sub-micron or even nano-scale.
(2) Improvement of the level of intelligence.
The introduction of artificial intelligence technology enables 5-axis machine tools to automatically optimize the cutting speed, feed and other machining parameters according to the machining material, tool status and workpiece shape, and realize adaptive machining. At the same time, through the analysis of a large amount of processing data, predict equipment failure in advance, carry out preventive maintenance, and reduce equipment downtime.
(3) Deep integration with other technologies.
Combine with additive manufacturing and other technologies to realize additive and subtractive composite machining on the same equipment, which can both rapidly form complex structures through additive manufacturing and use five-axis machining to carry out high-precision surface treatment and detail machining. Integrate with virtual reality (VR) and augmented reality (AR) technology to provide operators with a virtual operation training environment, or provide real-time operation guidance and processing information display through AR technology during actual processing.
8.2 Function Expansion
(1) Sustainable development
The design of the machine tool will pay more attention to energy saving, and adopt high-efficiency motors, drive systems and energy-saving control systems to reduce the energy consumption of the equipment. For the processing of special materials, the traditional way of spraying cutting fluid and green manufacturing technology based on green environmental protection concepts are mainly adopted at present, such as dry cutting, low-temperature cooling cutting and low-temperature micro-lubrication and other green cutting technology, which reduces the use of cutting fluid while reducing the pollution of the environment. In addition, the choice of equipment materials and manufacturing processes will also be more environmentally friendly, easy to recycle and reuse.
(2) Enhanced composite function
In addition to the common milling, drilling, boring and reaming and other functions of the composite, but also with turning, grinding, additive manufacturing, laser and ultrasonic and other machining modes of in-depth fusion, the formation of multi-process, multi-functional composite machining centers. For example, a five-axis milling and turning composite machining center can be completed in a clamping complex rotary parts turning, milling and drilling and other processing, improving processing efficiency and accuracy, reducing the accumulation of errors.
(3) Miniaturization and Microminiaturization
To meet the micro-electromechanical systems (MEMS), micro-molds, precision medical equipment and precision watchmaking and other areas of demand for tiny parts processing, the future of five-axis machine tools will be miniaturized and miniaturized development. Subsequent five-axis machine tool companies will develop high-precision, high-resolution miniature five-axis machine tools, with the ability to use tiny tools and tiny cutting force control capabilities, to achieve precision machining of tiny parts.
8.3 Market Application
(1) Application fields
Continue to expand in the traditional aerospace, automotive manufacturing and mold processing, and other fields continue to deepen the application of the basis to precision optics, smart homes, low-altitude economic equipment and humanoid robot equipment and other industries to expand rapidly.
(2) Customized services increase
Different industries, different customers’ on the five-axis machining vary greatly; the future machine tool manufacturers will pay more attention to the specific needs of customers, to provide customized five-axis machining technology and equipment personalized solutions from the functional configuration of the equipment, machining stroke, precision requirements, fast moving speed and control system depth of customization to meet the customer’s individual production needs.
(3) Localization and globalization go hand in hand.
With the continuous breakthrough of technology and policy support, the localization rate of five-axis machining technology and equipment will continue to improve, and gradually realize the import substitution of high-end equipment and reduce the dependence on foreign brands.
8.4 Industrial Development
Industrial clusters and synergistic development will be strengthened. The five-axis machine tool industry will form a wider industrial cluster. All links in the industry chain, including host manufacturers, parts suppliers, system integrators and scientific research institutions etc., will strengthen synergistic cooperation. Through the establishment of industrial alliances and cooperation between industry, academia and research, etc., they will realize the sharing of resources and complement each other’s strengths, and work together to overcome the technical problems, promote the overall development of five-axis machining technology and equipment, and improve the overall competitiveness of the industry.
9. Conclusion
Five-axis machining technology and equipment have occupied a key position in the modern manufacturing industry, and play an indispensable role in the key areas of core industries. From the perspective of technological development, high precision, high speed and intelligence have become the main vein of technological development. Advanced control algorithms, high-precision sensor applications, so that the machining accuracy to continue to break through, approaching the sub-micron and even nanometer; high-speed cutting technology with high-performance cutting tools, will significantly shorten the machining cycle, improve productivity; intelligent technology is integrated into the machining process is to bring qualitative leap, the realization of the machining process of intelligent monitoring and adaptive adjustment.
Looking ahead, five-axis machining technology and equipment development prospects are broad and full of opportunities. As the core cornerstone of the manufacturing industry, its development level is an important symbol to measure the competitiveness of the national manufacturing industry. In the face of opportunities and challenges, we should unswervingly increase investment in scientific research, deepen the cooperation between industry, academia and research, build a perfect talent training system, make every effort to break through the key technological bottlenecks, and realize the independent and controllable development of five-axis machining technology and equipment.
This article was published in Metalworking (Cold Processing), Vol. 5, No. 1~9, pp. 13, 2025, by Fu Weiming, Shenyang Zhong
